BIGBADBOB

Thought I could hear the rear end howling today. So pulled the cover off and found all kinds of thin metal strips. Upon disassembly I found the shims on the gear side of the pinion shaft eaten up. So what causes this to happen and what do I do to rectify the problem?? The truck has 130,000 kilometers on it or about 100,000 miles. The truck has been serviced regularly and the oil was not dirty. There seems to be no other damage as the magnet picked up the pieces.
UPDATE
Got the truck back today $660 Canadian. Teck at the diff shop said the pinion shims were never put in the right place, he said to go and see DC and have them call him. I don't have luck but will try for some cash back.

Hottrodjim

BigBadBob,

I had the same situation. My rearend was knocking on accel/decelleration. The shims were shot. I had Four Wheel Direct redo the shims and bearings. The gears were fine. About two weeks later it was knocking again and they replaced the shims with a piece of machined shim stock instead of the individual shims. This seems to have resolved the problem but I am not certain what causes the shims to get beat up. I would seem to me that the rearend is not assembled properly if the shims are being beat out.